Bonding apparatus, bonding system, bonding method, and recording medium

ABSTRACT

A bonding apparatus configured to bond substrates includes a first holder configured to vacuum-exhaust a first substrate to attract and hold the first substrate on a bottom surface thereof; a second holder disposed under the first holder and configured to vacuum-exhaust a second substrate to attract and hold the second substrate on a top surface thereof; a rotator configured to rotate the first holder and the second holder relatively; a moving device configured to move the first holder and the second holder relatively in a horizontal direction; three position measurement devices disposed at the first holder or the second holder rotated by the rotator and configured to measure a position of the first holder or the second holder; and a controller configured to control the rotator and the moving device based on measurement results of the three position measurement devices.

CROSS-REFERENCE TO RELATED APPLICATION

This is a continuation application of U.S. patent application Ser. No. 16/347,856 filed on May 7, 2019, which is a U.S. national phase application under 35 U.S.C. § 371 of PCT Application No. PCT/JP2017/036657 filed on Oct. 10, 2017, which claims the benefit of Japanese Patent Application No. 2016-218579 filed on Nov. 9, 2016, the entire disclosures of which are incorporated herein by reference.

TECHNICAL FIELD

The various embodiments described herein pertain generally to a bonding apparatus configured to bond substrates, a bonding system equipped with the bonding apparatus, a bonding method using the bonding apparatus and a recording medium.

BACKGROUND ART

Recently, semiconductor devices are getting miniaturized. If a plurality of highly integrated semiconductor devices is placed on a horizontal plane and these semiconductor devices are connected by a wiring to be produced as a product, a wiring length is increased. As a result, resistance of the wiring is increased, and there is a concern that a wiring delay may be increased.

In this regard, there is proposed using a three-dimensional integration technique of stacking semiconductor devices three-dimensionally. In this three-dimensional integration technique, two sheets of semiconductor wafers (hereinafter, referred to as “wafers”) are bonded by using a bonding system described in, for example, Patent Document 1. By way of example, the bonding system is equipped with a surface modifying apparatus configured to modify to-be-bonded surfaces of wafers; a surface hydrophilizing apparatus configured to hydrophilize the surfaces of the wafers which are modified by the surface modifying apparatus; a bonding apparatus configured to bond the wafers having the surfaces which are hydrophilized by the surface hydrophilizing apparatus. In this bonding system, the surfaces of the wafers are modified in the surface modifying apparatus by performing a plasma processing on the surfaces of the wafers. Further, in the surface hydrophilizing apparatus, the surfaces of the wafers are hydrophilized by supplying pure water onto the surfaces thereof. Then, the wafers are bonded in the bonding apparatus by a Van der Waals force and a hydrogen bond (intermolecular force).

In the aforementioned bonding apparatus, one wafer (hereinafter, referred to as “upper wafer”) is held by using an upper chuck, and the other wafer (hereinafter, referred to as “lower wafer”) is held by a lower chuck provided under the upper chuck. While being held by these upper and lower chucks, the upper wafer and the lower wafer are bonded. Here, before the wafers are bonded, a position of the lower chuck with respect to the upper chuck in a horizontal direction is adjusted by moving the lower chuck in the horizontal direction with a moving device, and, also, a position of the lower chuck in a rotational direction (a direction of the lower chuck) is adjusted by rotating the lower chuck with a moving device.

-   Patent Document 1: Japanese Patent Laid-open Publication No.     2015-018919

In the bonding apparatus of the aforementioned Patent Document 1, however, when adjusting the position of the lower chuck in the rotational direction after adjusting the position of the lower chuck in the horizontal direction, a rotation shaft may be deviated in the horizontal direction when rotating the lower chuck depending on control accuracy of the moving device. In such a case, the horizontal position of the lower chuck with respect to the upper chuck may be deviated, and, resultantly, the upper wafer and the lower wafer may be deviated from each other when they are bonded. In this regard, there is still a room for improvement in bonding the wafers.

SUMMARY

The purpose of exemplary embodiments described herein is to provide a technique capable of performing a bonding processing of bonding substrates appropriately by performing position adjustment of a first holder configured to hold a first substrate and a second holder configured to hold a second substrate appropriately.

In one exemplary embodiment, a bonding apparatus configured to bond substrates includes a first holder configured to vacuum-exhaust a first substrate to attract and hold the first substrate on a bottom surface thereof; a second holder disposed under the first holder and configured to vacuum-exhaust a second substrate to attract and hold the second substrate on a top surface thereof; a rotator configured to rotate the first holder and the second holder relatively; a moving device configured to move the first holder and the second holder relatively in a horizontal direction; a position measurement device disposed at the first holder or the second holder rotated by the rotator and configured to measure a position of the first holder or the second holder; and a controller configured to control the rotator and the moving device based on measurement results of the position measurement device, and the position measurement device comprises a first position measurement device, a second position measurement device and a third position measurement device, and a distance between the first position measurement device and the second position measurement device is same as a distance between the first position measurement device and the third position measurement device.

According to the exemplary embodiment, since the position of the first holder or the second holder is measured by using the three position measurement devices, eccentric amounts (deviation amounts) between the first holder and the second holder in the rotational direction, the X direction and the Y direction can be respectively calculated, and correction amounts for the first holder or the second holder in the rotational direction, the X direction and the Y direction can be calculated from the measurement results. By controlling the rotator and the moving device based on the calculation results, the relative position between the first holder and the second holder can be appropriately adjusted. Accordingly, the bonding between the first substrate held by the first holder and the second substrate held by the second holder can be carried out appropriately after the position adjustment.

In another exemplary embodiment, a bonding system equipped with a bonding apparatus comprises a processing station equipped with the bonding apparatus; and a carry-in/out station configured to place thereon multiple first substrates, multiple second substrates or multiple combined substrates each obtained by bonding the first substrate and the second substrate, and configured to carry the first substrates, the second substrates or the combined substrates into/from the processing station. The processing station comprises a surface modifying apparatus configured to modify surfaces of the first substrate or the second substrate to be bonded; a surface hydrophilizing apparatus configured to hydrophilize the surface of the first substrate or the second substrate modified by the surface modifying apparatus; and a transfer device configured to transfer the first substrates, the second substrates or the combined substrates with respect to the surface modifying apparatus, the surface hydrophilizing apparatus and the bonding apparatus. In the bonding apparatus, the first substrate and the second substrate having the surfaces hydrophilized by the surface hydrophilizing apparatus are bonded.

In still another exemplary embodiment, in a bonding method of bonding substrates by using a bonding apparatus, the bonding apparatus comprises a first holder configured to vacuum-exhaust a first substrate to attract and hold the first substrate on a bottom surface thereof; a second holder disposed under the first holder and configured to vacuum-exhaust a second substrate to attract and hold the second substrate on a top surface thereof; a rotator configured to rotate the first holder and the second holder relatively; a moving device configured to move the first holder and the second holder relatively in a horizontal direction; and a position measurement device disposed at the first holder or the second holder rotated by the rotator and configured to measure a position of the first holder or the second holder, and the position measurement device comprises a first position measurement device, a second position measurement device and a third position measurement device, and a distance between the first position measurement device and the second position measurement device is same as a distance between the first position measurement device and the third position measurement device. The bonding method comprises measuring the position of the first holder or the second holder by using the three position measurement devices; and adjusting a relative position between the first holder and the second holder by controlling the rotator and the moving device based on measurement results in the measuring of the position.

In yet another exemplary embodiment, there is provided a computer-readable recording medium having stored thereon computer-executable instructions that, in response to execution, cause the bonding apparatus to perform the bonding method.

According to the exemplary embodiments as described above, it is possible to perform the bonding processing of bonding the substrates appropriately by performing the position adjustment of the first holder configured to hold the first substrate and the second holder configured to hold the second substrate appropriately.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view schematically illustrating a configuration of a bonding system according to an exemplary embodiment.

FIG. 2 is a side view schematically illustrating an internal configuration of the bonding system according to the exemplary embodiment.

FIG. 3 is a side view schematically illustrating a configuration of an upper wafer and a lower wafer.

FIG. 4 is a transversal cross sectional view schematically illustrating a configuration of a bonding apparatus.

FIG. 5 is a longitudinal cross sectional view schematically illustrating the configuration of the bonding apparatus.

FIG. 6 is a longitudinal cross sectional view schematically illustrating an upper chuck, an upper chuck rotator and a lower chuck.

FIG. 7 is a plan view schematically illustrating a configuration of the upper chuck rotator.

FIG. 8 is an explanatory diagram showing individual dimensions when calculating an eccentric amount of the upper chuck with respect to the lower chuck.

FIG. 9 is a flowchart illustrating major processes of a wafer bonding processing.

FIG. 10 is an explanatory diagram illustrating a state in which a center of the upper wafer and a center of the lower wafer are pressed to be brought into contact with each other.

DETAILED DESCRIPTION

Hereinafter, various exemplary embodiments will be described with reference to accompanying drawings. Further, it should be noted that the exemplary embodiments are not intended to be anyway limiting.

1. Configuration of Bonding System

First, a configuration of a bonding system according to an exemplary embodiment will be discussed. FIG. 1 is a plan view schematically illustrating a configuration of a bonding system 1. FIG. 2 is a side view schematically illustrating an internal configuration of the bonding system 1.

In the bonding system 1, two sheets of wafers W_(U) and W_(L) as substrates are bonded, for example, as shown in FIG. 3. Hereinafter, a wafer placed at an upper side is referred to as “upper wafer W_(U)” as a first substrate, and a wafer placed at a lower side is referred to as “lower wafer W_(L)” as a second substrate. Further, in surfaces of the upper wafer W_(U), a bonding surface to be bonded is referred to as “front surface W_(U1),” and a surface opposite to the front surface W_(U1) is referred to as “rear surface W_(U2).” Likewise, in surfaces of the lower wafer W_(L), a bonding surface to be bonded is referred to as “front surface W_(L1),” and a surface opposite to the front surface W_(L1) is referred to as “rear surface W_(L2).” In the bonding system 1, a combined wafer W_(T) as a combined substrate is formed by bonding the upper wafer W_(U) and the lower wafer W_(L).

The bonding system 1 is equipped with, as depicted in FIG. 1, a carry-in/out station 2 and a processing station 3 connected as a single body. The carry-in/out station 2 is configured to carry cassettes C_(U), C_(L) and C_(T), which accommodates therein a plurality of wafers W_(U), a plurality of wafers W_(L) and a plurality of combined wafers W_(T), respectively, to/from the outside. The processing station 3 is equipped with various kinds of processing apparatuses configured to perform preset processings on the wafers W_(U) and W_(L) and the combined wafer W_(T).

The carry-in/out station 2 includes a cassette placing table 10. The cassette placing table 10 is equipped with a multiple number of, for example, four cassette placing plates 11. The cassette placing plates 11 are arranged in a horizontal X direction (up-and-down direction of FIG. 1). When the cassettes C_(U), C_(L), C_(T) are carried to/from the outside of the bonding system 1, the cassettes C_(U), C_(L), C_(T) are placed on these cassette placing plates 11. In this way, the carry-in/out station 2 is configured to be capable of holding a multiple number of upper wafers W_(U), a multiple number of lower wafers W_(L) and a multiple number of combined wafers W_(T). Further, the number of the cassette placing tables 11 is not limited to the example shown in the present exemplary embodiment, and may be set as required. Furthermore, one of the cassettes may be used to collect abnormal wafers. That is, an abnormal combined wafer, which has suffered a problem in bonding between an upper wafer W_(U) and a lower wafer W_(L), is separately accommodated in a cassette to be separated from other normal combined wafers W_(T). In the present exemplary embodiment, one of the cassettes C_(T) is used for the collection of the abnormal wafers, and other cassettes C_(T) are used for the accommodation of the normal combined wafers W_(T).

The carry-in/out station 2 is equipped with a wafer transfer section 20 adjacent to the cassette placing table 10. Provided in the wafer transfer section 20 is a wafer transfer device 22 configured to be movable along a transfer path 21 which is extended in the X direction. The wafer transfer device 22 is configured to be movable in a vertical direction and pivotable around a vertical axis (θ direction). The transfer device 22 is configured to transfer the wafers W_(U) and W_(L) and the combined wafer W_(T) between the cassettes C_(U), C_(L) and C_(T) placed on the cassette placing plates 11 and transition devices 50 and 51 of a third processing block G3 of the processing station 3 to be described later.

A multiple number of, for example, three processing blocks G1, G2 and G3 equipped with various kinds of apparatuses are provided in the processing station 3. For example, the first processing block G1 is provided at a front side (negative X-directional side of FIG. 1) of the processing station 3, and the second processing block G2 is provided at a rear side (positive X-directional side of FIG. 1) of the processing station 3. Further, the third processing block G3 is provided near the carry-in/out station 2 (at a negative Y direction side of FIG. 1) of the processing station 3.

Provided in the first processing block G1 is a surface modifying apparatus 30 configured to modify the surfaces W_(U1) and W_(L1) of the wafers W_(U) and W_(L). In the surface modifying apparatus 30, an oxygen gas or a nitrogen gas as a processing gas is formed into plasma under a decompressed atmosphere to be ionized. These oxygen ions or nitrogen ions are irradiated to the surfaces W_(U1) and W_(L1) of the wafers W_(U) and W_(L), so the surfaces W_(U1) and W_(L1) are plasma-processed to be modified.

By way of example, in the second processing block G2, a surface hydrophilizing apparatus 40 and a bonding apparatus 41 are arranged in a horizontal Y direction in this sequence from the carry-in/out station 2. The surface hydrophilizing apparatus 40 is configured to hydrophilize and clean the surfaces W_(U1) and W_(L1) of the wafers W_(U) and W_(L) with, for example, pure water. The bonding apparatus 41 is configured to bond the wafers W_(U) and W_(L). A configuration of the bonding apparatus 41 will be elaborated later.

In this surface hydrophilizing apparatus 40, while rotating the wafer W_(U) (W_(L)) held by, for example, a spin chuck, the pure water is supplied onto the corresponding wafer W_(U) (W_(L)). The supplied pure water is diffused on the surface W_(U1) (W_(L1)) of the wafer W_(U) (W_(L)), so that the surface W_(U1) (W_(L1)) is hydrophilized.

By way of example, in the third processing block G3, the transition devices 50 and 51 for the wafers W_(U) and W_(L) and the combined wafer W_(T) are arranged in two levels in this order from the bottom, as illustrated in FIG. 2.

Further, as illustrated in FIG. 1, a wafer transfer region 60 is formed in an area surrounded by the first processing block G1 to the third processing block G3. For example, a wafer transfer device 61 is disposed in the wafer transfer region 60.

The wafer transfer device 61 is equipped with, for example, a transfer arm 61 a which is configured to be movable in a vertical direction and a horizontal direction (Y direction and X direction) and pivotable around a vertical axis. The wafer transfer device 61 is moved within the wafer transfer region 60 and transfers the wafers W_(U) and W_(L) and the combined wafer W_(T) into preset apparatuses within the first processing block G1, the second processing block G2 and the third processing block G3 which are adjacent to the wafer transfer region 60.

As depicted in FIG. 1, the bonding system 1 is equipped with a controller 70. The controller 70 may be implemented by, for example, a computer and includes a program storage (not shown). The program storage stores therein programs for controlling processings on the wafers W_(U) and W_(L) and the combined wafer W_(T) in the bonding system 1. Further, the program storage also stores therein programs for controlling operations of the aforementioned various kinds of the processing apparatuses and a driving system such as the transfer devices to thereby allow a wafer bonding processing to be described later to be performed in the bonding system 1. Further, the programs are stored in, for example, a computer-readable recording medium H such as a hard disk (HD), a flexible disk (FD), a compact disk (CD), a magnet optical disk (MO) or a memory card, and may be installed to the controller 70 from the recording medium H.

2. Configuration of Bonding Apparatus

Now, a configuration of the bonding apparatus 41 will be explained.

<2-1. Overall Configuration of Bonding Apparatus>

As depicted in FIG. 4, the bonding apparatus 41 includes a processing chamber 100 having a hermetically sealable inside. A carry-in/out opening 101 for the wafers W_(U) and W_(L) and the combined wafer W_(T) is formed at a lateral side of the processing vessel 100 on the side of the wafer transfer region 60. An opening/closing shutter 102 for the carry-in/out opening 101 is provided at the carry-in/out opening 101.

The inside of the processing vessel 100 is partitioned into a transfer region T1 and a processing region T2 by an inner wall 103. The aforementioned carry-in/out opening 101 is formed at the lateral side of the processing vessel 100 in the transfer region T1. Further, the inner wall 103 is also provided with a carry-in/out opening 104 for the wafers W_(U) and W_(L) and the combined wafer W_(T).

A transition 110 configured to temporarily place thereon the wafers W_(U) and W_(L) and the combined wafer W_(T) is provided at a positive Y-directional side of the transfer region T1. The transition 110 has, for example, two levels and is capable of holding any two of the wafers W_(U) and W_(L) and the combined wafer W_(T) at the same time.

A wafer transfer device 111 is provided within the transfer region T1. The wafer transfer device 111 is equipped with a transfer arm 111 a configured to be movable in the vertical direction and the horizontal direction (X direction and Y direction) and also pivotable around a vertical axis, as shown in FIG. 4 and FIG. 5. The wafer transfer device 111 is capable of transferring the wafers W_(U) and W_(L) and the combined wafer W_(T) within the transfer region T1 or between the transfer region T1 and the processing region T2.

A position adjusting device 120 configured to adjust a direction of the wafers W_(U) and W_(L) in the horizontal direction is provided at a negative Y-directional side of the transfer region T1. The position adjusting device 120 includes: a base 121 equipped with a holder (not shown) configured to hold and rotate the wafer W_(U) (W_(L)); and a detector 122 configured to detect a position of a notch of the wafer W_(U) (W_(L)). The position adjusting device 120 adjusts the position of the notch of the wafer W_(U) (W_(L)) by detecting the position of the notch with the detector 122 while rotating the wafer W_(U) (W_(L)) held by the base 121. Accordingly, the horizontal positions of the wafer W_(U) (W_(L)) is adjusted. Further, a structure configured to hold the wafer W_(U) (W_(L)) in the base 121 is not particularly limited. By way of non-limiting example, various structures such as a pin chuck structure or a spin chuck structure may be utilized.

Furthermore, an inverting device 130 configured to invert a front surface and a rear surface of the upper wafer W_(U) is provided in the transfer region T1. The inverting device 130 is equipped with a holding arm 131 configured to hold the upper wafer W_(U). The holding arm 131 is extended in the horizontal direction (X direction). Further, the holding arm 131 is provided with holding members 132 respectively arranged at four positions. The holding members 132 are configured to hold the upper wafer W_(U).

The holding arm 131 is supported by a driver 133 including, for example, a motor or the like. The holding arm 131 is configured to be rotatable around a horizontal axis by the driver 133. Further, the holding arm 131 is rotatable around the driver 133 and movable in the horizontal direction (X direction). Another driver (not shown) including, for example, a motor or the like is provided under the driver 133. The driver 133 can be moved in the vertical direction along a vertically extended supporting column 134 by this another driver. The upper wafer W_(U) held by the holding members 132 can be rotated around the horizontal axis and can also be moved in the vertical direction and the horizontal direction by the driver 133. Further, the upper wafer W_(U) held by the holding members 132 can be moved between the position adjusting device 120 and an upper chuck 140 to be described later by being rotated around the driver 133.

The upper chuck 140 and a lower chuck 141 are disposed in the processing region T2. The upper chuck 140 serves as a first holder configured to attract and hold the upper wafer W_(U) on a bottom surface thereof, and the lower chuck 141 serves as a second holder configured to place the lower wafer W_(L) on a top surface thereof while attracting and holding the lower wafer W_(L). The lower chuck 141 is provided under the upper chuck 140 and is configured to be disposed to face the upper chuck 140. That is, the upper wafer W_(U) held by the upper chuck 140 and the lower wafer W_(L) held by the lower chuck 141 can be arranged to face each other.

The upper chuck 140 is held by an upper chuck rotator 150 disposed above the upper chuck 140. The upper chuck rotator 150 is configured to rotate the upper chuck 140 around a vertical axis as will be described later. Further, the upper chuck rotator 150 is provided at a ceiling surface of the processing vessel 100.

The upper chuck rotator 150 is equipped with an upper imaging device 151 configured to image the front surface W_(L1) of the lower wafer W_(L) held by the lower chuck 141. That is, the upper imaging device 151 is disposed adjacent to the upper chuck 140. The upper imaging device 151 may be, by way of example, but not limitation, a CCD camera.

The lower chuck 141 is supported by a lower chuck stage 160 provided under the lower chuck 141. The lower chuck stage 160 is equipped with a lower imaging device 161 configured to image the front surface W_(U1) of the upper wafer W_(U) held by the upper chuck 140. That is, the lower imaging device 161 is disposed adjacent to the lower chuck 141. The lower imaging device 161 may be, by way of example, but not limitation, a CCD camera.

The lower chuck stage 160 is supported by a first lower chuck mover 162 disposed under the lower chuck stage 160. Further, the first lower chuck mover 162 is supported by a supporting table 163. The first lower chuck mover 162 is configured to move the lower chuck 141 in the horizontal direction (X direction) as will be described later. Moreover, the first lower chuck mover 162 is configured to move the lower chuck 141 in the vertical direction.

The supporting table 163 is fastened to a pair of rails 164 which is disposed at a bottom side of the supporting table 163 to be elongated in the horizontal direction (X direction). The supporting table 163 is configured to be movable along the rails 164 by the first lower chuck mover 162. Further, the first lower chuck mover 162 is moved by, for example, a linear motor (not shown) provided along the rails 164.

The rails 164 are provided at a second lower chuck mover 165. The second lower chuck mover 165 is fastened to a pair of rails 166 which is provided at a bottom side of the second lower chuck mover 165 to be elongated in the horizontal direction (Y direction). The second lower chuck mover 165 is configured to be movable along the rails 166, that is, to move the lower chuck 141 in the horizontal direction (Y direction). The second lower chuck mover 165 is moved by, for example, a linear motor (not shown) provided along the rails 166. The rails 166 are disposed on a placing table 167 provided at a bottom surface of the processing vessel 100.

Further, in the present exemplary embodiment, the first lower chuck mover 162 and the second lower chuck mover 165 constitutes a moving device of the present disclosure.

<2-2. Configuration of Upper Chuck and Upper Chuck Rotator>

Now, a detailed configuration of the upper chuck 140 and the upper chuck rotator 150 of the bonding apparatus 41 will be described.

The upper chuck 140 is of a pin chuck type, as shown in FIG. 6. The upper chuck 140 has a main body 170 having a diameter larger than a diameter of the upper wafer W_(U) when viewed from the top. A plurality of pins 171 configured to be brought into contact with the rear surface W_(U2) of the upper wafer W_(U) is provided at a bottom surface of the main body 170. Further, an outer rib 172 having the same height as the pins 171 and configured to support a periphery of the rear surface W_(U2) of the upper wafer W_(U) is provided at a periphery of the bottom surface of the main body 170. The outer rib 172 is annularly formed at an outside of the pins 171.

Further, an inner rib 173 having the same height as the pins 171 and configured to support the rear surface W_(U2) of the upper wafer W_(U) is provided at an inside of the outer rib 172 on the bottom surface of the main body 170. The inner rib 173 is formed in a ring shape to be concentric with the outer rib 172. A region 174 inside the outer rib 172 (hereinafter, sometimes referred to as “suction region 174”) is partitioned into a first suction region 174 a inside the inner rib 173 and a second suction region 174 b outside the inner rib 173.

First suction openings 175 a for vacuum-exhausting the upper wafer W_(U) in the first suction region 174 a are formed at the bottom surface of the main body 170. The first suction openings 175 a are formed at, for example, four positions in the first suction region 174 a. The first suction openings 175 a are connected to first suction lines 176 a which are provided within the main body 170. Further, the first suction lines 176 a are connected with a first vacuum pump 177 a.

In addition, second suction openings 175 b for vacuum-exhausting the upper wafer W_(U) in the second suction region 174 b are formed at the bottom surface of the main body 170. The second suction openings 175 b are formed at, for example, two positions within the second suction region 174 b. The second suction openings 175 b are connected to second suction lines 176 b provided within the main body 170. Further, the second suction lines 176 b are connected with a second vacuum pump 177 b.

By vacuum-exhausting the suction regions 174 a and 174 b formed by being surrounded by the upper wafer W_(U), the main body 170 and the outer rib 172 through the suction openings 175 a and 175 b, respectively, the suction regions 174 a and 174 b are decompressed. At this time, since an atmosphere at the outside of the suction regions 174 a and 174 b is under an atmospheric pressure, the upper wafer W_(U) is pressed toward the suction regions 174 a and 174 b by the atmospheric pressure as much as a decompressed amount, so that the upper wafer W_(U) is attracted to and held by the upper chuck 140. Further, the upper chuck 140 is configured to be capable of vacuum-exhausting the upper wafer W_(U) through the first suction region 174 a and the second suction region 174 b individually.

In this case, since the outer rib 172 supports the periphery of the rear surface W_(U2) of the upper wafer W_(U), the upper wafer W_(U) is appropriately vacuum-exhausted, including the periphery thereof. Therefore, the entire surface of the upper wafer W_(U) is attracted to and held by the upper chuck 140, and flatness of the upper wafer W_(U) can be reduced and the upper wafer W_(U) can thus be flattened.

Furthermore, since the heights of the pins 171 are uniform, flatness of the bottom surface of the upper chuck 140 can be further reduced. In this way, by flattening the bottom surface (by reducing the flatness of the bottom surface) of the upper chuck 140, the upper wafer W_(U) held by the upper chuck 140 can be suppressed from suffering from a deformation in the vertical direction.

Further, since the rear surface W_(U2) of the upper wafer W_(U) is supported by the pins 171, it is easy for the upper wafer W_(U) to be separated from the upper chuck 140 when releasing the vacuum-exhaust of the upper wafer W_(U) by the upper chuck 140.

The upper chuck 140 is provided with a through hole 178 which is formed through a center of the main body 170 in a thickness direction of the main body 170. The center of this main body 170 corresponds to a center of the upper wafer W_(U) held by and attracted to the upper chuck 140. A leading end of the actuator 191 of a pressing member 190 to be described later is inserted through this through hole 178.

The upper chuck rotator 150 is equipped with an upper chuck stage 180 provided on a top surface of the main body 170 of the upper chuck 140 and configured to hold the upper chuck 140, as depicted in FIG. 6 and FIG. 7. The upper chuck stage 180 has an open top and has a hollow cylindrical shape. When viewed from the top, the upper chuck stage 180 has the substantially same shape as the main body 170. Provided at an outer circumferential surface of the upper chuck stage 180 is a supporting member 181 configured to support the upper chuck stage 180 and mounted to the ceiling surface of the processing vessel 100. A slight gap is formed between the outer circumferential surface of the upper chuck stage 180 and an inner circumferential surface of the supporting member 181.

The pressing member 190 configured to press the center of the upper wafer W_(U) is provided on a bottom surface within the upper chuck stage 180. The pressing member 190 has the actuator 191 and a cylinder 192.

The actuator 191 is configured to generate a constant pressure in a certain direction by air supplied from an electro-pneumatic regulator (not shown), and is capable of generating the pressure constantly regardless of a position of a point of application of the pressure. The actuator 191 is capable of controlling a pressing load applied to the center of the upper wafer W_(U) by the air from the electro-pneumatic regulator while the actuator 191 comes into contact with the center of the upper wafer W_(U). Further, the leading end of the actuator 191 is vertically movable up and down through the through hole 178 by the air from the electro-pneumatic regulator.

The actuator 191 is supported by the cylinder 192. The cylinder 192 is capable of moving the actuator 191 in the vertical direction by a driver having, for example, a motor embedded therein.

As stated above, the pressing member 190 controls the pressing load with the actuator 191 and controls the movement of the actuator 191 with the cylinder 192. The pressing member 190 is capable of pressing the center of the upper wafer W_(U) and a center of the lower wafer W_(L) when bonding of the wafers W_(U) and W_(L) to be described later is performed.

The supporting member 181 is equipped with, as depicted in FIG. 7, a rotating device 200 configured to rotate the upper chuck stage 180 (and the upper chuck 140). The rotating device 200 is in contact with the outer circumferential surface of the upper chuck stage 180 and is capable of rotating the upper chuck state 180 with a driver which has, for example, a motor embedded therein.

Further, the supporting member 181 is provided with fixing parts 210 configured to hold the upper chuck stage 180 in place. The fixing parts 210 are equi-spaced at four positions along the outer circumferential surface of the upper chuck stage 180. Each fixing part 210 blows air toward the outer circumferential surface of the upper chuck stage 180, thus achieves centering of the upper chuck stage 180 and holds the upper chuck stage 180 in place.

Further, the supporting member 181 is equipped with linear scales 221 to 223 as position measurement devices each configured to measure a position of the upper chuck stage 180, that is, a position of the upper chuck 140. The linear scales 221 to 223 include scales 221 a to 223 a provided at the outer circumferential surface of the upper chuck stage 180 and detection heads 221 b to 223 b configured to read the scales 221 a to 223 a, respectively. Further, for the measuring method of the position of the upper chuck 140 by the linear scales 221 to 223, a commonly known method may be utilized.

In the three linear scales 221 to 223, the first linear scale 221 is disposed to face the rotating device 200 on a central line of the upper chuck stage 180. Further, the second linear scale 222 and the third linear scale 223 are disposed at positions where they form a central angle of 90 degrees with respect to the first linear scale 221, and are disposed to face each other on the central line of the upper chuck stage 180. That is, a distance between the first linear scale 221 and the second linear scale 222 and a distance between the first linear scale 221 and the third linear scale 223 are same.

Furthermore, through the linear scale is used as the position measurement device in the present exemplary embodiment, the position measurement device is not limited thereto as long as it is capable of measuring the position of the upper chuck 140. By way of non-limiting example, a displacement meter may be used as the position measurement device.

<2-3. Position Adjustment of Upper Chuck>

The first linear scale 221 is connected to a servo amplifier (not shown), and the servo amplifier is connected to the controller 70. That is, the first linear scale 221 is used for a servo control (full close control), and a measurement result of the first linear scale 221 is used to adjust a position of the upper chuck 140 in the rotational direction (0 direction) around the vertical axis thereof, as will be described later.

Further, the second linear scale 222 and the third linear scale 223 are respectively connected to the controller 70. Measurement results of the three linear scales 221 to 223 are used to adjust a position of the upper chuck 140 in the horizontal direction (X direction and Y direction) as will be described later, and also used, when required, to adjust the position of the upper chuck 140 in the rotational direction (0 direction). To elaborate, to adjust these positions of the upper chuck 140, the eccentric amount (deviation amount) of the upper chuck 140 with respect to the lower chuck 141 is calculated from the measurement results of the three linear scales 221 to 223.

Here, a method of calculating the aforementioned eccentric amount of the upper chuck 140 will be explained. FIG. 8 is an explanatory diagram showing dimensions required to calculate the eccentric amount of the upper chuck 140. In FIG. 8, a reference numeral 140 a refers to a center point of the upper chuck 140 which is not eccentric, that is, located at a right position, and a reference numeral 140 b indicates a center point of the upper chuck 140 which is eccentric. Measurement results L1 to L3 of the three linear scales 221 to 223 are respectively represented by the following expressions (1) to (3). Further, the measurement results L1 to L3 of the linear scales 221 to 223 are encoder values (absolute values) counted up in the clockwise direction.

L1=y+Rθ  (1)

L2=−x+Rθ  (2)

L3=x+Rθ  (3)

-   -   L1: An encoder value of the first linear scale 221     -   L2: An encoder value of the second linear scale 222     -   L3: An encoder value of the third linear scale 223     -   x: An eccentric amount of the upper chuck 140 with respect to         the lower chuck 141 in X direction     -   y: An eccentric amount of the upper chuck 140 with respect to         the lower chuck 141 in Y direction     -   θ: An eccentric amount (rotation amount) of the upper chuck 140         with respect to the lower chuck 141     -   R: Radius of the upper chuck 140

If the expressions (1) to (3) are organized with respect to x, y and 0, the following expressions (4) to (6) are derived.

x=(L3−L2)/2  (4)

y=L1−(L3+L2)/2  (5)

θ=(L3+L2)/2R  (6)

<2-4. Configuration of Lower Chuck>

Now, a detailed configuration of the lower chuck 141 of the bonding apparatus 41 will be explained.

The lower chuck 141 is of a pin chuck type, the same as the upper chuck 140, as shown in FIG. 6. The lower chuck 141 has a main body 230 having a diameter larger than a diameter of the lower wafer W_(L) when viewed from the top. A plurality of pins 231 configured to be brought into contact with the rear surface W_(L2) of the lower wafer W_(L) is provided at a top surface of the main body 230. Further, an outer rib 232 having the same height as the pins 231 and configured to support a periphery of the rear surface W_(L2) of the lower wafer W_(L) is provided at a periphery of the top surface of the main body 230. The outer rib 232 is annularly formed at an outside of the pins 231.

Further, an inner rib 233 having the same height as the pins 231 and configured to support the rear surface W_(L2) of the lower wafer W_(L) is provided at an inside of the outer rib 232 on the top surface of the main body 230. The inner rib 233 is formed in a ring shape to be concentric with the outer rib 232. A region 234 inside the outer rib 232 (hereinafter, sometimes referred to as “suction region 234”) is partitioned into a first suction region 234 a inside the inner rib 233 and a second suction region 234 b outside the inner rib 233.

A first suction opening 235 a for vacuum-exhausting the lower wafer W_(L) in the first suction region 234 a is formed at the top surface of the main body 230. The first suction opening 235 a is formed at, for example, a single position in the first suction region 234 a. The first suction opening 235 a is connected to a first suction line 236 a which is provided within the main body 230. Further, the first suction line 236 a is connected with a first vacuum pump 237 a.

In addition, second suction openings 235 b for vacuum-exhausting the lower wafer W_(L) in the second suction region 234 b are formed at the top surface of the main body 230. The second suction openings 235 b are formed at, for example, two positions within the second suction region 234 b. The second suction openings 235 b are connected to second suction lines 236 b provided within the main body 230. Further, the second suction lines 236 b are connected with a second vacuum pump 237 b.

By vacuum-exhausting the suction regions 234 a and 234 b formed by being surrounded by the lower wafer W_(L), the main body 230 and the outer rib 232 through the suction openings 235 a and 235 b, respectively, the suction regions 234 a and 234 b are decompressed. At this time, since an atmosphere at the outside of the suction regions 234 a and 234 b is under the atmospheric pressure, the lower wafer W_(L) is pressed toward the suction regions 234 a and 234 b by the atmospheric pressure as much as a decompressed amount, so that the lower wafer W_(L) is attracted to and held by the lower chuck 141. Further, the lower chuck 141 is configured to be capable of vacuum-exhausting the lower wafer W_(L) through the first suction region 234 a and the second suction region 234 b individually.

In this case, since the outer rib 232 supports the periphery of the rear surface W_(L2) of the lower wafer W_(L), the lower wafer W_(L) is appropriately vacuum-exhausted, including the periphery thereof. Therefore, the entire surface of the lower wafer W_(L) is attracted to and held by the lower chuck 141, and flatness of the lower wafer W_(L) can be reduced and the lower wafer W_(L) can thus be flattened.

Furthermore, since the heights of the pins 231 are uniform, flatness of the top surface of the lower chuck 141 can be further reduced. In this way, by flattening the top surface (by reducing the flatness of the top surface) of the lower chuck 141, the lower wafer W_(L) held by the lower chuck 141 can be suppressed from suffering from a deformation in a vertical direction.

Further, since the rear surface W_(L2) of the lower wafer W_(L) is supported by the pins 231, it is easy for the lower wafer W_(L) to be separated from the lower chuck 141 when releasing the vacuum-exhaust of the lower wafer W_(L) by the lower chuck 141.

The lower chuck 141 is provided with through holes (not shown) which are formed in a thickness direction of the main body 230 at, e.g., three positions in the vicinity of a center of the main body 230. Elevating pins provided under the first lower chuck mover 162 are inserted through these through holes.

Guide members (not shown) are provided at a periphery of the main body 230 to suppress each of the wafers W_(U) and W_(L) and the combined wafer W_(T) from falling down by being bounced off or slid off the lower chuck 141. The guide members are equi-spaced at plural positions, for example, four positions at the periphery of the main body 230.

The operations of the individual components of the bonding apparatus 41 are controlled by the aforementioned controller 70.

3. Bonding Method

Now, a bonding method for the wafers W_(U) and W_(L) performed by the bonding system 1 configured as described above will be explained. FIG. 9 is a flowchart illustrating an example of main processes of such a wafer bonding processing.

First, a cassette C_(U) accommodating the upper wafers W_(U), a cassette C_(L) accommodating the lower wafers W_(L) and an empty cassette C_(T) are placed on the preset cassette placing plates 11 of the carry-in/out station 2. Then, an upper wafer W_(U) is taken out of the cassette C_(U) by the wafer transfer device 22 and is transferred to the transition device 50 of the third processing block G3 of the processing station 3.

Subsequently, the upper wafer W_(U) is transferred into the surface modifying apparatus 30 of the first processing block G1 by the wafer transfer device 61. In the surface modifying apparatus 30, an oxygen gas or a nitrogen gas as the processing gas is excited into plasma to be ionized under the preset decompressed atmosphere. The oxygen ions or the nitrogen ions are irradiated to the front surface W_(U1) of the upper wafer W_(U), and the front surface W_(U1) is plasma-processed. As a result, the front surface W_(U1) of the upper wafer W_(U) is modified (process S1 of FIG. 9).

Then, the upper wafer W_(U) is transferred into the surface hydrophilizing apparatus 40 of the second processing block G2 by the wafer transfer device 61. In the surface hydrophilizing apparatus 40, pure water is supplied onto the upper wafer W_(U) while rotating the upper wafer W_(U) held by the spin chuck. The supplied pure water is diffused on the front surface W_(U1) of the upper wafer W_(U), and hydroxyl groups (silanol groups) adhere to the front surface W_(U1) of the upper wafer W_(U) modified in the surface modifying apparatus 30, so that the front surface W_(U1) is hydrophilized. Further, the front surface W_(U1) of the upper wafer W_(U) is cleaned by the pure water (process S2 of FIG. 9).

Thereafter, the upper wafer W_(U) is transferred into the bonding apparatus 41 of the second processing block G2 by the wafer transfer device 61. The upper wafer W_(U) carried into the bonding apparatus 41 is then transferred into the position adjusting device 120 through the transition 110 by the wafer transfer device 111. Then, the direction of the upper wafer W_(U) in the horizontal direction is adjusted by the position adjusting device 120 (process S3 of FIG. 9).

Then, the upper wafer W_(U) is delivered onto the holding arm 131 of the inverting device 130 from the position adjusting device 120. Then, in the transfer region T1, by inverting the holding arm 131, the front surface and the rear surface of the upper wafer W_(U) are inverted (process S4 of FIG. 9). That is, the front surface W_(U1) of the upper wafer W_(U) is turned to face downwards.

Thereafter, the holding arm 131 of the inverting device 130 is rotated around the driver 133 to be located under the upper chuck 140. The upper wafer W_(U) is then transferred to the upper chuck 140 from the inverting device 130. The rear surface W_(U2) of the upper wafer W_(U) is attracted to and held by the upper chuck 140 (process S5 of FIG. 9). To elaborate, by operating the vacuum pumps 177 a and 177 b, the upper wafer W_(U) is vacuum-exhausted through the suction openings 175 a and 175 b in the suction regions 174 a and 174 b, so that the upper wafer W_(U) is attracted to and held by the upper chuck 140.

While the above-described processes S1 to S5 are being performed on the upper wafer W_(U), processings are performed on the lower wafer W_(L). First, the lower wafer W_(L) is taken out of the cassette C_(L) by the wafer transfer device 22 and transferred into the transition device 50 of the processing station 3.

Subsequently, the lower wafer W_(L) is transferred into the surface modifying apparatus 30 by the wafer transfer device 61, and the front surface W_(L1) of the lower wafer W_(L) is modified (process S6 of FIG. 9). Further, the modification of the front surface W_(L1) of the lower wafer W_(L) in the process S6 is the same as the above-described process S1.

Thereafter, the lower wafer W_(L) is transferred into the surface hydrophilizing apparatus 40 by the wafer transfer device 61, so that the front surface W_(L1) of the lower wafer W_(L) is hydrophilized and cleaned (process S7 of FIG. 9). The hydrophilizing and the cleaning of the front surface W_(L1) of the lower wafer W_(L) in the process S7 are the same as those in the above-described process S2.

Afterwards, the lower wafer W_(L) is transferred into the bonding apparatus 41 by the wafer transfer device 61. The lower wafer W_(L) carried into the bonding apparatus 41 is transferred into the position adjusting device 120 through the transition 110 by the wafer transfer device 111. Then, the direction of the lower wafer W_(L) in the horizontal direction is adjusted by the position adjusting device 120 (process S8 of FIG. 9).

Then, the lower wafer W_(L) is transferred onto the lower chuck 141 by the wafer transfer device 111, and the rear surface W_(L2) is attracted to and held by the lower chuck 141 (process S9 of FIG. 9). To elaborate, by operating the vacuum pumps 237 a and 237 b, the lower wafer W_(L) is vacuum-exhausted through the suction openings 235 a and 235 b in the suction regions 234 a and 234 b, so that the lower wafer W_(L) is attracted to and held by the lower chuck 141.

Subsequently, the position adjustment of the upper wafer W_(U) held by the upper chuck 140 and the lower wafer W_(L) held by the lower chuck 141 is performed.

First, initial adjustment of the positions of the upper wafer W_(U) and the lower wafer W_(L) in the rotational direction (horizontal direction) is performed by using the upper imaging device 151 and the lower imaging device 161. To elaborate, the lower chuck 141 is moved in the horizontal direction (X direction and Y direction) by the first lower chuck mover 162 and the second lower chuck mover 165, and preset reference points (for example, two points at a periphery) on the front surface W_(L1) of the lower wafer W_(L) are imaged in sequence by using the upper imaging device 151. Concurrently, preset reference points (for example, two points at a periphery) on the front surface W_(U1) of the upper wafer W_(U) are imaged in sequence by using the lower imaging device 161. The obtained images are outputted to the controller 70. Based on the images obtained by the upper imaging device 151 and the lower imaging device 161, the controller 70 rotates the upper chuck 140 by the rotating device 200 to a position where the reference points of the upper wafer W_(U) and the lower wafer W_(L) are overlapped, that is, where the directions of the upper wafer W_(U) and the lower wafer W_(L) become identical. In this way, the positions of the upper wafer W_(U) and the lower wafer W_(L) in the rotational direction are initially adjusted (process S10 of FIG. 9).

Here, the position adjustment using the upper imaging device 151 and the lower imaging device 161 is performed only in this process S10, and the position adjustments in the subsequent processes S11 and S12 are performed by using the linear scales 221 to 223 as will be described later. Particularly, in the process S11, though the position of the upper chuck 140 in the rotational direction is adjusted by using the first linear scale 221, initial states of the upper wafer W_(U) held by the upper chuck 140 and the lower wafer W_(L) held by the lower chuck 141 in the rotational direction cannot be observed with the first linear scale 221. For this reason, in the aforementioned process S10, the positions of the upper wafer W_(U) and the lower wafer W_(L) in the rotational direction are initially adjusted.

After the process S10, the position of the upper chuck 140 is measured by using the first linear scale 221. The measurement result of the first linear scale 221, that is, the encoder value L1 of the first linear scale 221 is outputted to the controller 70. The controller 70 calculates a correction amount for the upper chuck 140 in the rotational direction based on the encoder value L1 of the first linear scale 221 such that an eccentric amount θ of the upper chuck 140 with respect to the lower chuck 141 in the rotational direction falls within a preset threshold value, e.g., ±0.2 μrad. Then, the controller 70 controls the rotating device 200 based on this correction amount. As the upper chuck 140 is rotated by the rotating device 200 as much as the correction amount, the position of the upper chuck 140 with respect to the lower chuck 141 in the rotational direction is adjusted (process S11 of FIG. 9).

In the process S11, the first linear scale 221 spaced farthest from the rotating device 200 is used. By way of example, if the upper chuck 140 and the lower chuck 141 are deviated from each other in the rotational direction, an influence of this deviation is largely reflected in this encoder value L1 of the first linear scale 221 as compared to an encoder value L2 of the second linear scale 222 or an encoder value L3 of the third linear scale 223, for example. Accordingly, the position of the upper chuck 140 in the rotational direction can be adjusted more appropriately.

Further, in the process S11, when rotating the upper chuck 140 by the rotating device 200, the upper chuck stage 180 is centered by the fixing parts 210.

In addition, in the process S11, the rotating device 200 may be controlled such that the eccentric amount θ of the upper chuck 140 in the rotational direction becomes zero. Further, if the encoder value L1 of the first linear scale 221 is found to fall within a preset threshold value as a result of the measurement by the first linear scale 221, it may not be required to rotate the upper chuck 140 with the rotating device 200.

In the above-described process S11, when rotating the upper chuck 140 by the rotating device 200, a center point (rotation axis) of the upper chuck 140 may be deviated from the center point 140 a to the center point 140 b in the horizontal direction, as shown in FIG. 8. By way of example, in case that the control accuracy of the rotating device 200 is low, the center point of the upper chuck 140 is deviated in the horizontal direction. Further, though the upper chuck 140 is centered by the air from the four fixing parts 210, the center point of the upper chuck 140 may be deviated in the horizontal direction depending on the air balance from these fixing parts 210.

Thus, the horizontal position of the upper chuck 140 is then adjusted. To elaborate, the position of the upper chuck 140 is first measured by using the three linear scales 221 to 223. The measurement results of the three linear scales 221 to 223, that is, the encoder values L1 to L3 of the three linear scales 221 to 223 are outputted to the controller 70. Based on the encoder values L1 to L3 of the linear scales 221 to 223, the controller 70 calculates eccentric amounts x, y and θ of the upper chuck 140 with respect to the lower chuck 141 in the X direction, the Y direction and the θ direction, respectively, from the following expressions (4) to (6).

x=(L3−L2)/2  (4)

y=L1−(L3+L2)/2  (5)

θ=(L3+L2)/2R  (6)

Further, the controller 70 calculates the correction amounts for the upper chuck 140 in the horizontal direction (X direction and Y direction) such that the eccentric amount x of the upper chuck 140 in the X direction and the eccentric amount y of the upper chuck 140 in the Y direction fall within a preset threshold value, e.g., 1 μm. Then, the controller 70 controls the first lower chuck mover 162 and the second lower chuck mover 165 based on these correction amounts. As the upper chuck 140 is moved by the first lower chuck mover 162 and the second lower chuck mover 165 as much as the correction amounts, the position of the upper chuck 140 with respect to the lower chuck 141 in the horizontal direction is adjusted (process S12 of FIG. 9).

In the process S12, since the distance between the first linear scale 221 and the second linear scale 222 is equal to the distance between the first linear scale 221 and the third linear scale 223, simple expressions such as the aforementioned expressions (4) to (6) may be used. Here, if these distances are different, an equation for calculating the eccentric amounts of the upper chuck 140 would be complicated, resulting in a complicated control as well. In the present exemplary embodiment, the horizontal position of the upper chuck 140 can be adjusted through the simple control.

Furthermore, in the process S12, the first lower chuck mover 162 and the second lower chuck mover 165 may be controlled such that the eccentric amount x of the upper chuck 140 in the X direction and the eccentric amount y of the upper chuck 140 in the Y direction both become zero. Further, if each of the encoder values L1 to L3 of the linear scales 221 to 223 falls within the preset threshold value as a result of the measurement by the three linear scales 221 to 223, it is not needed to move the upper chuck 140 in the horizontal direction by the first lower chuck mover 162 and the second lower chuck mover 165.

Moreover, in the process S12 of the present exemplary embodiment, the position of the upper chuck 140 in the horizontal direction is adjusted. By way of example, if the eccentric amount θ of the upper chuck 140 in the rotational direction calculated from the expression (6) does not fall within the preset threshold value, e.g., ±0.2 μrad, the position of the upper chuck 140 in the rotational direction may be further adjusted. To be specific, in the controller 70, the correction amount for the upper chuck 140 in the rotational direction is calculated based on the eccentric amount θ of the upper chuck 140 in the rotational direction. Then, the upper chuck 140 is rotated by the correction amount with the rotating device 200, so that the position of the upper chuck 140 with respect to the lower chuck 141 in the rotational direction is adjusted.

By performing the above-stated processes S10 to S12, the position adjustment between the upper chuck 140 and the lower chuck 141 is performed, and the positions of the upper wafer W_(U) held by the upper chuck 140 and the lower wafer W_(L) held by the lower chuck 141 in the rotational direction and the horizontal direction are adjusted.

Thereafter, by moving the lower chuck 141 vertically upwards by the first lower chuck mover 162, the position adjustment between the upper chuck 140 and the lower chuck 141 in the vertical direction is performed, so that the position adjustment between the upper wafer W_(U) held by the upper chuck 140 and the lower wafer W_(L) held by the lower chuck 141 in the vertical direction is carried out (process S13 of FIG. 9). Then, the upper wafer W_(U) and the lower wafer W_(L) are located at the preset positions while facing each other.

Subsequently, a bonding processing of bonding the upper wafer W_(U) held by the upper chuck 140 and the lower wafer W_(L) held by the lower chuck 141 is performed.

First, as depicted in FIG. 10, the actuator 191 is lowered by the cylinder 192 of the pressing member 190. As the actuator 191 is moved down, the center of the upper wafer W_(U) is lowered while being pressed. At this time, the preset pressing load is applied to the actuator 191 by the air supplied from the electro-pneumatic regulator. The center of the upper wafer W_(U) and the center of the lower wafer W_(L) are pressed to be in contact with each other by the pressing member 190 (process S14 of FIG. 9). At this time, by stopping the operation of the vacuum pump 177 a, the vacuum-exhaust of the upper wafer W_(U) from the first suction openings 175 a in the first suction region 174 a is stopped, while carrying on the operation of the second vacuum pump 177 b to vacuum-exhaust the second suction region 174 b from the second suction openings 175 b. When pressing the center of the upper wafer W_(U) with the pressing member 190, the periphery of the upper wafer W_(U) can still be held by the upper chuck 140.

Accordingly, the bonding is started between the center of the upper wafer W_(U) and the center of the lower wafer W_(L) which are pressed against each other (as indicted by a bold line in FIG. 10). That is, since the front surface W_(U1) of the upper wafer W_(U) and the front surface W_(L1) of the lower wafer W_(L) have been modified in the processes S1 and S6, respectively, a Van der Waals force (intermolecular force) is generated between the front surfaces W_(U1) and W_(L1), so that the front surfaces W_(U1) and W_(L1) are bonded. Further, since the front surface W_(U1) of the upper wafer W_(U) and the front surface W_(L1) of the lower wafer W_(L) have been hydrophilized in the processes S2 and S7, respectively, hydrophilic groups between the front surfaces W_(U1) and W_(L1) are hydrogen-bonded (intermolecular force), so that the front surfaces W_(U1) and W_(L1) are firmly bonded.

Then, by stopping the operation of the second vacuum pump 177 b while still pressing the center of the upper wafer W_(U) and the center of the lower wafer W_(L) with the pressing member 190, the vacuum-exhaust of the upper wafer W_(U) from the second suction openings 175 b in the second suction region 174 b is stopped. Accordingly, the upper wafer W_(U) falls down on the lower wafer W_(L). The upper wafer W_(U) gradually falls on the lower wafer W_(L) to be in contact with each other, and the aforementioned bonding between the front surfaces W_(U1) and W_(L1) by the Van der Waals force and the hydrogen-bond is gradually expanded. Accordingly, the entire front surface W_(U1) of the upper wafer W_(U) and the entire front surface W_(L1) of the lower wafer W_(L) are brought into contact with each other, so that the upper wafer W_(U) and the lower wafer W_(L) are bonded (process S15 of FIG. 9).

In this process S15, since the rear surface W_(U2) of the upper wafer W_(U) is supported by the pins 171, the upper wafer W_(U) is easily separated from the upper chuck 140 when the vacuum-exhaust of the upper wafer W_(U) by the upper chuck 140 is released. Thus, the expansion (bonding wave) of the bonding between the upper wafer W_(U) and the lower wafer W_(L) takes place in a circular shape, so that the upper wafer W_(U) and the lower wafer W_(L) are appropriately bonded.

Thereafter, the actuator 191 of the pressing member 190 is raised up to the upper chuck 140. Further, by stopping the operation of the vacuum pumps 237 a and 237 b and thus stopping the vacuum-exhaust of the lower wafer W_(L) in the suction region 234, the attracting and holding of the lower wafer W_(L) by the lower chuck 141 is stopped. At this time, since the rear surface W_(L)z of the lower wafer W_(L) is supported by the pins 231, the lower wafer W_(L) is easily separated from the lower chuck 141 when the vacuum-exhaust of the lower wafer W_(L) by the lower chuck 141 is released.

Thereafter, the combined wafer W_(T) obtained by the bonding of the upper wafer W_(U) and the lower wafer W_(L) is transferred to the transition device 51 by the wafer transfer device 61, and then is transferred into the cassette C_(T) of the preset cassette placing table 11 by the wafer transfer device 22 of the carry-in/out station 2. Through these processes, the series of operations of the bonding processing for the wafers W_(U) and W_(L) is completed.

According to the exemplary embodiment as described above, in the process S11, the position of the upper chuck 140 with respect to the lower chuck 141 in the rotational direction is adjusted by using the measurement result of the first linear scale 221. At this time, by using the first linear scale 221 which is located at the farthest position from the rotating device 200, the deviation of the upper chuck 140 and the lower chuck 141 in the rotational direction can be investigated more appropriately than in cases of using the other linear scales 222 and 223. Thus, the position of the upper chuck 140 in the rotational direction can be appropriately adjusted.

Further, in the process S12, the horizontal position of the upper chuck 140 with respect to the lower chuck 141 is adjusted by using the measurement results of the three linear scales 221 to 223. Accordingly, even if the horizontal position of the upper chuck 140 is deviated when adjusting the position of the upper chuck 140 in the rotational direction in the process S11, it is possible to correct and adjust the horizontal position of the upper chuck 140 appropriately in the process S12.

Furthermore, in this process S12, in case that the eccentric amount θ of the upper chuck 140 in the rotational direction is not within the preset threshold value, the position of the upper chuck 140 in the rotational direction can be appropriately adjusted.

Since the relative positions between the upper chuck 140 and the lower chuck 141 can be appropriately adjusted in the processes S11 and S12 as stated above, the bonding between the upper wafer W_(U) held by the upper chuck 140 and the lower wafer W_(L) held by the lower chuck 141 can be appropriately carried out.

Conventionally, in case of further performing the position adjustment after adjusting the positions of the upper wafer W_(U) and the lower wafer W_(L) by using the upper imaging device 151 and the lower imaging device 161 in the process S10, it takes time to accomplish this position adjustment as the upper imaging device 151 and the lower imaging device 161 are used again. According to the present exemplary embodiment, however, since this position adjustment is performed by using the linear scales 221 to 223 in the processes S11 and S12, the position adjustment can be carried out in a short time. Therefore, a throughput of the wafer bonding processing can be bettered.

Moreover, since the bonding system 1 of the present exemplary embodiment is equipped with the surface modifying apparatus 30, the surface hydrophilizing apparatus 40 and the bonding apparatus 41, the bonding of the wafers W_(U) and W_(L) can be conducted efficiently within the single system. Therefore, the throughput of the wafer bonding processing can be further improved.

4. Other Exemplary Embodiments

Now, other exemplary embodiments of the present disclosure will be explained.

In the bonding apparatus 41 according to the above-described exemplary embodiment, the second linear scale 222 and the third linear scale 223 are disposed at the positions where they form the central angle of 90 degrees with respect to the first linear scale 221, and are disposed to face each other on the central line of the upper chuck stage 180. However, the arrangement of the second linear scale 222 and the third linear scale 223 is not limited thereto. The second linear scale 222 and the third linear scale 223 may be provided at positions where their central angle with respect to the first linear scale 221 forms an angel different from 90 degrees, e.g., 45 degrees, as long as the distance between the first linear scale 221 and the second linear scale 222 and the distance between the first linear scale 221 and the third linear scale 223 are same. If these distances are same even if the central angle is not 90 degrees, the eccentric amount of the upper chuck 140 can be calculated by using the simple equations as the expressions (4) to (6). Thus, the position adjustment of the upper chuck 140 can be carried out through the simple control.

Further, in the bonding apparatus 41 of the above-described exemplary embodiment, the upper chuck 140 is configured to be rotatable. However, the lower chuck 141 may be configured to be rotatable instead. In such a case, the three linear scales 221 to 223 are provided at the lower chuck 141. Further, both the upper chuck 140 and the lower chuck 141 may be configured to be rotatable. In such a case, the three linear scales 221 to 223 may be provided at either the upper chuck 140 or the lower chuck 141.

Moreover, in the bonding apparatus 41 according to the above-described exemplary embodiment, though the lower chuck 141 is configured to be movable in the horizontal direction, the upper chuck 140 may be configured to be movable in the horizontal direction instead, or both the upper chuck 140 and the lower chuck 141 may be configured to be movable in the horizontal direction. Likewise, though the lower chuck 141 is configured to be movable in the vertical direction, the upper chuck 140 may be configured to be vertically movable instead, or both the upper chuck 140 and the lower chuck 141 may be configured to be vertically movable.

In addition, in the bonding system 1 according to the above-stated exemplary embodiment, after the wafers W_(U) and the W_(L) are bonded in the bonding apparatus 41, the obtained combined wafer W_(T) may be heated to a preset temperature (annealing processing). By performing this heating processing on the combined wafer W_(T), bonding interfaces can be firmly bonded.

From the foregoing, it will be appreciated that the exemplary embodiment of the present disclosure has been described herein for purposes of illustration, and that various modifications may be made without departing from the scope and spirit of the present disclosure. Accordingly, the embodiment disclosed herein is not intended to be limiting. The scope of the inventive concept is defined by the following claims and their equivalents rather than by the detailed description of the exemplary embodiment. It shall be understood that all modifications and embodiments conceived from the meaning and scope of the claims and their equivalents are included in the scope of the inventive concept. In the present disclosure, the substrate is not limited to the wafer. The present disclosure is also applicable to various other types of substrates such as a FPD (Flat Panel Display), a mask reticle for photomask, and so forth.

The claims of the present application are different and possibly, at least in some aspects, broader in scope than the claims pursued in the parent application. To the extent any prior amendments or characterizations of the scope of any claim or cited document made during prosecution of the parent could be construed as a disclaimer of any subject matter supported by the present disclosure, Applicants hereby rescind and retract such disclaimer. Accordingly, the references previously presented in the parent applications may need to be revisited.

-   -   1: Bonding system     -   2: Carry-in/out station     -   3: Processing station     -   30: Surface modifying apparatus     -   40: Surface hydrophilizing apparatus     -   41: Bonding apparatus     -   61: Wafer transfer device     -   70: Controller     -   140: Upper chuck     -   141: Lower chuck     -   150: Upper chuck rotator     -   162: First lower chuck mover     -   165: Second lower chuck mover     -   200: Rotating device     -   221: First linear scale     -   222: Second linear scale     -   223: Third linear scale     -   W_(U): Upper wafer     -   W_(L): Lower wafer     -   W_(T): Combined wafer 

We claim:
 1. A bonding apparatus configured to bond substrates, comprising: a first holder configured to vacuum-exhaust a first substrate to attract and hold the first substrate on a bottom surface of the first holder; a second holder disposed under the first holder and configured to vacuum-exhaust a second substrate to attract and hold the second substrate on a top surface of the second holder; a rotator configured to rotate the first holder and the second holder relatively; a moving device configured to move the first holder and the second holder relatively in a horizontal direction; a position measurement device disposed at the first holder or the second holder rotated by the rotator and configured to measure a position of the first holder or the second holder; and a controller configured to control the rotator and the moving device based on measurement results of the position measurement device, wherein the position measurement device comprises a first position measurement device, a second position measurement device and a third position measurement device, and a distance between the first position measurement device and the second position measurement device is same as a distance between the first position measurement device and the third position measurement device.
 2. The bonding apparatus of claim 1, wherein the second position measurement device and the third position measurement device are respectively disposed at a position where a central angle with respect to the first position measurement device is 90 degrees.
 3. The bonding apparatus of claim 1, wherein the controller is configured to control the moving device based on the measurement results of the position measurement device after controlling the rotator based on a measurement result of the first position measurement device.
 4. The bonding apparatus of claim 1, wherein the controller is configured to control the rotator and the moving device based on the measurement results of the position measurement device after controlling the rotator based on a measurement result of the first position measurement device.
 5. The bonding apparatus of claim 1, wherein the rotator is provided at a periphery of the first holder or a periphery of the second holder, and the first position measurement device is provided at the periphery of the first holder or the periphery of the second holder, where the rotator is provided, to face the rotator on a central line of the first holder or the second holder.
 6. A bonding system equipped with a bonding apparatus configured to bond substrates, wherein the bonding apparatus comprises: a first holder configured to vacuum-exhaust a first substrate to attract and hold the first substrate on a bottom surface of the first holder; a second holder disposed under the first holder and configured to vacuum-exhaust a second substrate to attract and hold the second substrate on a top surface of the second holder; a rotator configured to rotate the first holder and the second holder relatively; a moving device configured to move the first holder and the second holder relatively in a horizontal direction; a position measurement device disposed at the first holder or the second holder rotated by the rotator, and configured to measure a position of the first holder or the second holder; and a controller configured to control the rotator and the moving device based on measurement results of the position measurement device, wherein the position measurement device comprises a first position measurement device, a second position measurement device and a third position measurement device, and a distance between the first position measurement device and the second position measurement device is same as a distance between the first position measurement device and the third position measurement device, and wherein the bonding system comprises: a processing station equipped with the bonding apparatus; and a carry-in/out station configured to place thereon multiple first substrates, multiple second substrates or multiple combined substrates each obtained by bonding the first substrate and the second substrate, and configured to carry the first substrates, the second substrates or the combined substrates into/from the processing station, wherein the processing station comprises: a surface modifying apparatus configured to modify surfaces of the first substrate or the second substrate to be bonded; a surface hydrophilizing apparatus configured to hydrophilize the surface of the first substrate or the second substrate modified by the surface modifying apparatus; and a transfer device configured to transfer the first substrates, the second substrates or the combined substrates with respect to the surface modifying apparatus, the surface hydrophilizing apparatus and the bonding apparatus, wherein, in the bonding apparatus, the first substrate and the second substrate having the surfaces hydrophilized by the surface hydrophilizing apparatus are bonded.
 7. A bonding method of bonding substrates by using a bonding apparatus, wherein the bonding apparatus comprises: a first holder configured to vacuum-exhaust a first substrate to attract and hold the first substrate on a bottom surface of the first holder; a second holder disposed under the first holder and configured to vacuum-exhaust a second substrate to attract and hold the second substrate on a top surface of the second holder; a rotator configured to rotate the first holder and the second holder relatively; a moving device configured to move the first holder and the second holder relatively in a horizontal direction; and a position measurement device disposed at the first holder or the second holder rotated by the rotator and configured to measure a position of the first holder or the second holder, wherein the position measurement device comprises a first position measurement device, a second position measurement device and a third position measurement device, and a distance between the first position measurement device and the second position measurement device is same as a distance between the first position measurement device and the third position measurement device, and wherein the bonding method comprises: measuring the position of the first holder or the second holder by using the position measurement device; and adjusting a relative position between the first holder and the second holder by controlling the rotator and the moving device based on measurement results in the measuring of the position.
 8. The bonding method of claim 7, further comprising: measuring the position of the first holder or the second holder by using the first position measurement device; adjusting the relative position between the first holder and the second holder by controlling the rotator based on a measurement result in the measuring of the position of the first holder or the second holder by using the first position measurement device; measuring the position of the first holder or the second holder by using the position measurement device; and adjusting the relative position between the first holder and the second holder by controlling the moving device based on the measurement results in the measuring of the position of the first holder or the second holder by using the position measurement device.
 9. The bonding method of claim 7, further comprising: measuring the position of the first holder or the second holder by using the first position measurement device; adjusting the relative position between the first holder and the second holder by controlling the rotator based on a measurement result in the measuring of the position of the first holder or the second holder by using the first position measurement device; measuring the position of the first holder or the second holder by using the position measurement device; and adjusting the relative position between the first holder and the second holder by controlling the rotator and the moving device based on the measurement results in the measuring of the position of the first holder or the second holder by using the position measurement device.
 10. The bonding method of claim 7, wherein the rotator is provided at a periphery of the first holder or a periphery of the second holder, and the first position measurement device is provided at the periphery of the first holder or the periphery of the second holder, where the rotator, is provided, to face the rotator on a central line of the first holder or the second holder.
 11. A computer-readable recording medium having stored thereon computer-executable instructions that, in response to execution, cause a bonding apparatus to perform a bonding method, wherein the bonding apparatus comprises: a first holder configured to vacuum-exhaust a first substrate to attract and hold the first substrate on a bottom surface of the first holder; a second holder disposed under the first holder and configured to vacuum-exhaust a second substrate to attract and hold the second substrate on a top surface of the second holder; a rotator configured to rotate the first holder and the second holder relatively; a moving device configured to move the first holder and the second holder relatively in a horizontal direction; and a position measurement device disposed at the first holder or the second holder rotated by the rotator and configured to measure a position of the first holder or the second holder, wherein the position measurement device comprises a first position measurement device, a second position measurement device and a third position measurement device, and a distance between the first position measurement device and the second position measurement device is same as a distance between the first position measurement device and the third position measurement device, and wherein the bonding method comprises: measuring the position of the first holder or the second holder by using the position measurement device; and adjusting a relative position between the first holder and the second holder by controlling the rotator and the moving device based on measurement results in the measuring of the position. 